Access floor panel

ABSTRACT

An access floor panel is disclosed having improved load-bearing strength. One access floor panel in accordance with the present invention includes an upper plate having a surface to support loads and a lower plate being substantially parallel with the upper plate. A core is disposed between the upper and lower plates and a reinforcing member disposed in the core.

FIELD OF THE INVENTION

[0001] The present invention relates generally to flooring assemblies, and more particularly, to access floor panels for use in floor assemblies, commonly known as access floors, elevated or raised floors, false floors or pedestal floors.

BACKGROUND OF THE INVENTION

[0002] A wide variety of floor assemblies have been developed to provide a structural floor elevated above an existing or base floor of a building. The elevated floor typically creates an under floor space or area for the distribution of building services. These building services can include management of power, voice and data systems, and the distribution of heating, cooling and ventilation services.

[0003] The elevated floor usually consists of a plurality of rectangular or square floor panels. The floor panels are typically supported above the base floor at each panel corner with pedestals. Bridge channels or stringers may be installed between the pedestals to provide lateral stability and increased strength of the elevated floor.

[0004] The floor panels used in creating an elevated floor can have a variety of constructions. The floor panels may have a wood structure or a cement core formed between two metal sheets. Floor panels made of a wood structure are usually relatively low in cost and light in weight. However, these floor panels are lower in strength and less resistant to fire. Although the cement core panels have higher strength than wood structure panels, the cement core panels usually have a high cost-to-strength ratio relative to its thickness. These cement core panels can also have a plurality of dome-like projections formed in the bottom sheet that extend substantially through the core of the panels. The dome-like projections are arranged in certain geometric patterns to improve the strength of the panel. However, these dome-like projections can increase stamping costs, restrict the flow of air underneath the panels, and increase manufacturing costs.

SUMMARY OF THE INVENTION

[0005] In view of the above, the present invention provides an access floor panel that has a greater load bearing capacity than conventional floor panels. The access floor panel exhibits an improved strength to weight ratio and produces marginal deflections when loaded. The access floor panel is relatively simple in construction and lighter in weight than present floor panels. The reduction in the weight of the access floor panel allows the panel to be easily lifted and carried by installers, allowing the access or raised floors to be installed in a shorter period of time. Therefore, the cost of installation and transporting the panels to the installation site can be reduced.

[0006] The access floor panel in accordance with the present invention is relatively easy to manufacture and can be made thinner than conventional floor panels. As a result, the amount of material needed to construct a panel can be reduced, thereby decreasing manufacturing costs of the access floor panel. In addition, the access floor panel has a substantially flat bottom to enhance airflow beneath the panel and to facilitate the attachment of a plenum barrier.

[0007] The floor panel preferably includes a reinforcement member that minimizes deflection and displacement of the panel. The reinforcing member is embedded in the core of the access floor panel to strengthen the loading capacity of the floor panel. The reinforcing member preferably has a corrugated pattern.

[0008] A floor panel in accordance with the present invention includes an upper plate having a surface to support loads and a lower plate being substantially parallel with the upper plate. A core is disposed between the upper and lower plates and a reinforcing member disposed in the core.

[0009] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

[0010] The invention, together with attendant advantages, will be best understood by reference to the following detailed description of the preferred embodiment of the invention, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is a perspective view of a flooring assembly containing access floor panels in accordance with the present invention;

[0012]FIG. 2 is a perspective view of an access floor panel in accordance with the present invention;

[0013]FIG. 3 is a side view of the access floor panels of FIG. 2;

[0014]FIG. 4 is a top view of the access floor panels of FIG. 2;

[0015]FIG. 5 is a perspective view of one embodiment of a reinforcing member of an access floor panel of FIG. 2; and

[0016] FIGS. 6-8 are top views of various embodiments of access floor panels in accordance with the present invention.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0017] Before explaining the present embodiments in detail, it should be understood that the invention is not limited in its application or use to the details of construction and arrangement of parts illustrated in the accompanying drawings and description. It will be recognized that the illustrative embodiments in accordance with the invention may be implemented or incorporated in other embodiments, variations and modifications, and may be practiced or carried out in various ways. Furthermore, unless otherwise indicated, the terms and expressions employed herein have been chosen for the purpose of describing the illustrative embodiments of the present invention for the convenience of the reader and are not for the purpose of limitation.

[0018] Referring now to the drawings, and more particularly to FIG. 1, an exemplary embodiment of an elevated floor 100 is illustrated. The elevated floor 100 is constructed with access floor panels 102 in accordance with the present invention. The access floor panels 102 provide a continuous floor surface that is spaced from an existing or base floor 104. The access floor panels 102 are supported at their corners by pedestals 106 that rest on the base floor 104. The pedestals 106 can be secured to the base floor 104 by fasteners or adhesives. The pedestals 106 may be vertically adjusted to change the overall height of the elevated floor 100 with respect to the base floor 104. Such access floor panels can be used in computer rooms and offices, since various building services such as heating, air conditioning, wiring and the like are installed in the area below the floor.

[0019] The access floor panels 102 are substantially identical in construction and are generally square in shape. The access floor panels 102 are preferably about 1.25 inches thick with each side having a length of about twenty-four (24) inches. It will be recognized that the floor panels 102 can have any suitable configuration, size, and thickness depending upon the particular flooring application.

[0020] The access floor panels 102 have an improved strength to weight ratio and an increased load bearing capacity. The access floor panels 102 can withstand various loads of office furniture, computers and other equipment. The access floor panels 102 are relatively simple in construction and produce marginal deflections when loaded. The access floor panels are also light in weight to allow installers to install the floor panels faster and more easily, thereby reducing installation costs. In addition, changes and repairs to the building services (i.e., heating) provided in the area under the floors can be easily accomplished by merely removing the appropriate floor panels 102 to provide access to the building service involved. Further, changes in the layout of the services to the building and/or office can be readily made.

[0021] The access floor panels 102 are relatively easy to manufacture and are preferably thinner than conventional floor panels. As a result, the amount of material needed to construct the access floor panels can be reduced, thereby decreasing manufacturing costs of the access floor panels. The access floor panels 102 also have a substantially flat bottom to enhance airflow beneath the panels and to facilitate the attachment of a plenum barrier.

[0022] As shown in FIG. 2, each access floor panel 102 of the elevated floor 100 preferably includes an upper or top plate 110, a lower plate or pan 112, and an interior section 114. The lower plate 112 is generally rectangular or square and is preferably made of metal. It will be recognized that the lower plate 112 may be constructed from a variety of other materials, including metal, plastic, fiberglass and any other suitable material. The lower plate 112 is preferably fabricated from a single sheet of galvanized steel having a thickness of about {fraction (1/16)} of an inch. It will be recognized that the lower plate 112 can have any suitable thickness depending on the particular flooring application and can be constructed from any suitable number of metal sheets.

[0023] The lower plate 112 of the access floor panel 100 includes a bottom 116 and peripheral sidewalls 118. As shown in FIG. 3, the bottom 116 of the lower plate 112 has a top and bottom surface 120 and 122, which are preferably substantially flat. The sidewalls 118 of the lower plate 112 preferably extend generally perpendicularly upward from the bottom 116 of the lower plate 112. It will be recognized that the sidewalls 118 may slope at any suitable angle with respect to the bottom 116 of the lower plate 112, such as an angle between twenty-five (25) and ninety (90) degrees. The sidewalls 118 of the lower plate 112 are preferably attached or bonded to the upper plate 110.

[0024] The interior section 114 of the access floor panel 102 includes a structural core or fill 124 and a rigid reinforcing or support member 126. The reinforcing member 126 is preferably embedded in the structural core 124 to strengthen the core 124 and the loading capacity of the access floor panel 102. The reinforcing member 126 may be secured to the sidewalls 118 of the lower plate 112 or may be formed within the core 126. The reinforcing member 126 preferably has a corrugated pattern.

[0025] The core 124 of the interior section 114 is appropriately one (1) inch thick and preferably comprises a lightweight, high-strength concrete mix which is poured directly into the lower plate 112 and allowed to set. It will be recognized that the core 124 can be made from a variety of other materials including, but not limited to, resins, wood, fiberglass, vinyl, rubber, Styrofoam, and plastic as well as any other suitable material. Alternatively, the core 124 may comprise a high-density wood particle core that can be structurally bonded to the bottom 116 of the lower plate 112 and upper plate 110.

[0026] The reinforcing member 126 of the interior section 114 is generally square and preferably constructed from metal. It will be recognized the reinforcing member 126 can be fabricated from a variety of other materials including, but not limited to, resins, wood, concrete, fiberglass, vinyl, rubber, Styrofoam, plastic or any other suitable material. The reinforcing member 126 can be solid (see FIG. 2) or perforated (see FIG. 5). The reinforcing member 126 is positioned within the interior section 114 and preferably spaced from the upper and lower plates 110 and 112.

[0027] As shown in FIGS. 2 and 3, the reinforcing member 126 preferably has a corrugated structure or pattern having a plurality of corrugations 128 forming peaks 130 and valleys or grooves 132. The corrugations 128 are spaced-apart from and generally parallel to each other. The reinforcing member 126 provides local support and added stiffness and strength to the access floor panel 102, particularly with respect to lateral forces applied thereto. The reinforcing member 126 also minimizes deflection and displacement of the access floor panel 102. As a result, when vertical forces are placed on the access floor panel 102, the reinforcing member 126 resists the radially outwardly directed shear force exerted on the access floor panel 102.

[0028] Referring now to FIG. 4, the reinforcing member 126 is preferably divided into a plurality of quadrants or sections 134, 136, 138, and 140 that are divided by imaginary lines 142 and 144. Although the reinforcement member 126 is divided into four sections, it is contemplated that the reinforcing member 126 can be divided into any suitable number of sections. Preferably, the sections are generally square and have substantially the same size. Each section of the reinforcing member 126 contains a corrugated pattern oriented in a different direction (i.e., perpendicular) than the corrugated pattern in an adjacent section. It is contemplated that the reinforcing member 126 can be configured in many different geometric patterns or shapes, including, but not limited to, rectangular, circular or the like (see FIGS. 6-8). It will also be recognized that the corrugated pattern of a section can be oriented at any suitable angle with respect to the corrugated pattern of an adjacent pattern.

[0029] As shown in FIGS. 2 and 4, sections 134 and 140 of the reinforcing member 126 have corrugations running parallel to edge 146 and perpendicular to edge 148 of the access floor panel 102. Similarly, sections 136 and 138 of the reinforcing member 126 have corrugations running parallel to edge 148 and perpendicular to edge 146 of the access floor panel 102. Preferably, the corrugated pattern of each section 134, 136, 138, and 140 includes a plurality of corrugations forming peaks and valleys. Although the access floor panel is illustrated having four (4) peaks and four (4) valleys, it will be recognized that each section of the reinforcing member 126 can have any suitable number of peaks and valleys. It will be also understood that different spacing, shapes and patterns of the reinforcing member 126 may also be employed without departing from the spirit of the invention.

[0030] The reinforcing member 126 may also have a sidewall (not shown) extending around its outer periphery to further strengthen the outer portion of each of the sections of the reinforcing member. The sidewall of the reinforcing member 126 can be attached or bonded to the edges of the reinforcing member. It will be recognized that the sidewalls 118 may be attached at any suitable angle to the reinforcing member 126, such as an angle between twenty-five (25) and ninety (90) degrees.

[0031] Referring again to FIG. 1, the upper plate 110 of the access floor panel 102 is generally rectangular or square in shape and is preferably made of metal. It will be recognized that the upper plate 110 may be constructed from a variety of materials, including, but not limited to, metal, plastic, fiberglass and any other suitable material. The upper plate 110 of the access floor panel 102 comprises a top surface 136 and a bottom surface 138, both of which are substantially flat. The upper plate 110 is preferably fabricated from a single sheet of galvanized steel having thickness of {fraction (1/16)} of an inch. It will be recognized that the upper plate 110 can have any suitable thickness depending on the particular flooring application.

[0032] An optional wearing surface (not shown) may be placed over the upper plate 110 of the access floor panel 102 to provide a desired working surface. For example, the upper plate 110 may be covered with carpet, vinyl, rubber, tile or any other suitable material. The wearing surface can be secured to the upper plate 110 by any suitable adhesive.

[0033] The access floor panel 102 in accordance with the present invention has an improved strength to weight ratio and an increased load bearing capacity. The floor panels can withstand various loads from office furniture, personnel, computers, and other equipment. The access floor panel 102 is relatively simple in construction and produces marginal deflections when loaded.

[0034] The access floor panel 102 in accordance with the present invention is relatively easy to manufacture and can be made thinner than conventional floor panels. As a result, the amount of material needed to construct a panel can be reduced, thereby decreasing manufacturing costs of the access floor panel 102. The access floor panel also has a substantially flat bottom to enhance airflow beneath the panel and to facilitate the attachment of a plenum barrier.

[0035] The access floor panel 102 is also light in weight to allow installers to install the floor panels more readily, thereby reducing installation costs. In addition, changes and repairs to the building services provided under the floors can be easily accomplished by merely removing the appropriate access floor panels 102 to provide access to the building service involved. Further, changes in the layout of the services to the building and/or office can be easily made.

[0036] Although the access floor panels have been described in detail by way of illustration and example, it should be understood that a wide range of changes and modifications can be made to the preferred embodiments described above without departing in any way from the scope and spirit of the present invention. Thus, the described embodiment is to be considered in all aspects only as illustrative and not restrictive, and the scope of the invention is, therefore, indicated by the appended claims rather than the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

What is claimed:
 1. An access floor panel comprising: a substantially flat upper plate having a surface to support loads; a substantially flat lower plate being substantially parallel with said upper plate; a core disposed between the upper and lower plate; a reinforcing member disposed in the core having a plurality of sections; and a first section of the reinforcing member having at least one corrugation oriented in a substantially different direction than a corrugation of a second section of the reinforcing member.
 2. The access floor panel of claim 1 wherein the core comprises a cementatious material.
 3. The access floor panel of claim 1 further comprising at least one pedestal to support the access flooring panels above a structural floor.
 4. The access floor panel of claim 1 wherein said access floor panel is substantially square.
 5. The access floor panel of claim 1 wherein the at least one corrugation of the first section is substantially perpendicular to the corrugation of the second section of the reinforcing member.
 6. The access floor panel of claim 1 wherein the reinforcing member is perforated.
 7. The access floor panel of claim 1 wherein the lower plate comprises a pan.
 8. The access floor panel of claim 1 wherein the first section of the reinforcing member is attached to the second member of the reinforcing member.
 9. A floor panel for a removable floor system comprising: a top; a bottom having a first edge and a second edge, the first edge being substantially perpendicular to the second edge; a reinforcing member disposed in the core having a plurality of sections; a first section of the reinforcing member having a plurality of corrugations extending in planes substantially parallel to the first edge of the bottom; and a second section of the reinforcing member having a plurality of corrugations extending in planes substantially parallel to the second edge of the bottom.
 10. The floor panel of claim 9 wherein the plurality of the corrugations of the first section of the reinforcing member comprise a plurality of peaks spaced apart from and substantially parallel to each other.
 11. The floor panel of claim 9 wherein the core comprises a cementatious material.
 12. The floor panel of claim 9 wherein said access floor panel is substantially square.
 13. The floor panel of claim 9 wherein the plurality of the corrugations of the first section of the reinforcing member are orientated substantially perpendicular to the plurality of the corrugations of the second section of the reinforcing member.
 14. The floor panel of claim 9 wherein the reinforcing member is perforated.
 15. The floor panel of claim 9 wherein the bottom comprises a pan.
 16. The floor panel of claim 9 wherein the first section of the reinforcing member is unattached to the second member of the reinforcing member.
 17. A floor panel for use in elevated floor assemblies comprising: a lower plate; a top plate; a core defined between said bottom and said top; and a support member embedded in the core having a plurality of sections; at least one of the plurality of sections having a corrugated pattern oriented substantially in a substantially different direction than a corrugated pattern of another section of the support member.
 18. The floor panel of claim 17 wherein the corrugated pattern of the first is orientated substantially perpendicular to the corrugated pattern of the other section.
 19. A floor panel comprising: an upper plate; a lower plate; a core disposed between the upper and lower plate; the floor panel having a first section and a second section; a first reinforcing member disposed in the first section having at least one corrugation; and a second reinforcing member disposed in the second section having at least one corrugation oriented in a different direction than the at least one corrugation of the first reinforcing member.
 20. A floor panel comprising: an upper plate; a lower plate being substantially parallel with the upper plate; a core disposed between the upper and lower plate; a reinforcing member embedded in the core, the reinforcing member being spaced apart from the upper and lower plates. 